What Is a Flying Shear Machine?

2025-04-04

A flying shear machine is an industrial workhorse designed to straighten and cut coiled metal wires (steel, stainless, copper, aluminum, etc.) with unmatched speed and accuracy. Combining straightening, cutting, and automation, it transforms raw materials into precision-cut straight segments for industries ranging from construction to hardware manufacturing. Here’s a technical breakdown of its design, specs, and advantages.

1. Structure & Applications

Key Components

Feeding System: Servo-driven rollers handle Ø1.2–7mm wires

Straightening Mechanism: 12-roller setup eliminates bends and twists

Cutting Module: Hydraulic or servo blades for burr-free cuts

Control Panel: PLC + HMI touchscreen (Chinese/English)

Safety Guards: Light curtains, emergency stops

Technical Scope

Parameter	Specification
Wire Diameter	Ø1.2–7mm (0.047–0.276")
Cutting Length	50mm–∞ (2"–∞)
Footprint	2.5m × 1.2m (8.2' × 3.9')
Ideal Production Rate	5–8 tons/day

Primary Industries:

Construction rebar processing

Automotive spring manufacturing

Electrical wire harness fabrication

2. Core Technical Specifications

Precision & Speed

Straightening Accuracy: ±0.5mm (0.02")

Max Speed: 120m/min (394 ft/min) – 10× faster than manual systems

Cut Quality: Laser-verified, zero deformation

Automation Features

PLC Programming: Set length/quantity → automatic batch production

Smart Compensation: Auto-adjusts for tool wear (±0.1mm self-correction)

Data Logging: Stores 200+ job profiles

3. Competitive Advantages

Efficiency & Stability

Servo-Driven Feed/Cut: Eliminates jams and downtime

Dual Modes:

Manual: For setup/testing (e.g., adjusting rollers)

Auto: Unattended 24/7 operation

Safety & Usability

Auto-Shutdown Triggers:

Wire breakage detection

Overload alerts (“Motor Torque Overload”)

Safety door open warnings

Intuitive Troubleshooting: Error codes with fix guides (e.g., “Return to Origin”)

Cost Savings

Labor: 1 operator manages 3+ machines

Material Waste: <1% vs. 5–8% manual cutting

Energy Use: 15kW/hour (50% less than hydraulic systems)

Case Study: Reinventing Rebar Processing

A Texas steel service center replaced manual shears with a Golden Spring flying shear machine, achieving:

✅ 8mm rebar cutting at 100m/min (328 ft/min)

✅ 98% length consistency across 10,000+ cuts

✅ ROI in 14 months via labor/material savings

Technical Comparison

Feature	Traditional Shear	Flying Shear Machine
Speed	12m/min (39 ft/min)	120m/min (394 ft/min)
Labor per Machine	1 operator	1 operator/3 machines
Cut Consistency	±2mm	±0.5mm